Sullair LS12 User manual

Part Number 02250058---882
eSullair Corporation
INDUSTRIAL AIR
COMPRESSOR
OPERATOR’S
LS --- 12 & LS --- 16
40, 50, 60, 75 & 100HP
STANDARD & 24 KT
(30, 37, 45, 55 & 75KW)
MANUAL AND
PARTS LIST
(U.S.A.)
KEEP FOR
FUTURE
REFERENCE

AIR CARE
SEMINAR TRAINING
Sullair AirCare Seminars are 3---day courses thatprovide hands---on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1---800---SULLAIR or 219---879---5451 (ext. 1816)
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
Section 1 PAGE
SAFETY 11.1 GENERAL
11.2 PERSONAL PROTECTIVE EQUIPMENT
11.3 PRESSURE RELEASE
21.4 FIRE AND EXPLOSION
21.5 MOVING PARTS
21.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
21.7 TOXIC AND IRRITATING SUBSTANCES
31.8 ELECTRICAL SHOCK
31.9 LIFTING
41.10 ENTRAPMENT
Section 2
DESCRIPTION 52.1 INTRODUCTION
52.2 DESCRIPTION OF COMPONENTS
52.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
62.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
82.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
92.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
11 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
11 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 13 3.1 TABLE OF SPECIFICATIONS
14 3.2 LUBRICATION GUIDE---STANDARD COMPRESSORS
(All 12 Series; 16 Series---60 and 75HP)
14 3.3 LUBRICATION GUIDE---STANDARD COMPRESSORS
(16 Series---100HP)
14 3.4 LUBRICATION GUIDE---24KT COMPRESSORS
Section 4
INSTALLATION 15 4.1 MOUNTING OF COMPRESSOR
15 4.2 VENTILATION AND COOLING
15 4.3 SERVICE AIR PIPING
15 4.4 COUPLING ALIGNMENT CHECK
15 4.5 FLUID LEVEL CHECK
15 4.6 ELECTRICAL PREPARATION
17 4.7 MOTOR ROTATION DIRECTION CHECK

TABLE OF CONTENTS
(CONTINUED)
Section 5 PAGE
OPERATION 19 5.1 GENERAL
19 5.2 PURPOSE OF CONTROLS
20 5.3 INITIAL START---UP PROCEDURE
21 5.4 SUBSEQUENT START---UP PROCEDURE
21 5.5 SHUTDOWN PROCEDURE
Section 6
MAINTENANCE 23 6.1 GENERAL
23 6.2 DAILY OPERATION
23 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
23 6.4 MAINTENANCE EVERY 4000 HOURS
23 6.5 FILTER MAINTENANCE
23 6.6 SEPARATOR MAINTENANCE
23 6.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
27 6.8 TROUBLESHOOTING
Section 7
ILLUSTRATIONS AND
PARTS LIST 31 7.1 PROCEDURE FOR ORDERING PARTS
31 7.2 RECOMMENDED SPARE PARTS LIST
34 7.3 MOTOR, FRAME, COMPRESSOR AND PARTS
(LS --- 12 SERIES)
38 7.4 MOTOR, FRAME, COMPRESSOR AND PARTS
(LS---16 SERIES 60---75HP)
40 7.5 MOTOR, FRAME, COMPRESSOR AND PARTS
(LS---16 SERIES 100HP)
42 7.6 AIR INLET SYSTEM (LS --- 12 AND LS --- 16 SERIES)
44 7.7 COMPRESSOR COOLING AND LUBRICATION SYSTEM
(AIR---COOLED, LS---12 SERIES 40 AND 50HP)
48 7.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM
(WATER---COOLED, LS---12 SERIES 40 AND 50HP)
52 7.9 COMPRESSOR COOLING AND LUBRICATION SYSTEM
(AIR --- COOLED, LS --- 12 SERIES 60HP,
AND LS---16 SERIES 60---75HP)
56 7.10 COMPRESSOR COOLING AND LUBRICATION SYSTEM
(AIR---COOLED, LS---16 SERIES 100HP)
60 7.11 COMPRESSOR COOLING AND LUBRICATION SYSTEM
(WATER --- COOLED, LS --- 12 SERIES 60HP,
AND LS---16 SERIES 60---75HP)
66 7.12 COMPRESSOR COOLING AND LUBRICATION SYSTEM
(WATER---COOLED, LS---16 SERIES 100HP)
72 7.13 COMPRESSOR DISCHARGE SYSTEM
(LS --- 12 AND LS --- 16 SERIES)
76 7.14 AIR --- COOLED COOLING AS SEMBLY (LS --- 12 AND LS --- 16 SERIES)
80 7.15 CAPACITY CONTROL SYSTEM (LS---12 AND LS---16 SERIES)

TABLE OF CONTENTS
(CONTINUED)
Section 7 PAGE
ILLUSTRATIONS AND
PARTS LIST
(CONTINUED) 84 7.16 INSTRUMENT PANEL AND PARTS (LS---12 AND LS---16 SERIES)
86 7.17 ELECTRO---PNEUMATIC CONTROL SYSTEM
(LS --- 12 AND LS --- 16 SERIES)
88 7.18 ELECTRIC CONTROL BOX (LS---12 AND LS---16 SERIES)
92 7.19 CANOPY ENCLOSURE AND PARTS (LS---12 AND LS---16 SERIES)
96 7.20 DECAL GROUP
104 7.21 WIRING DIAGRAM---SINGLE CONTROL
105 7.22 WIRING DIAGRAM---SINGLE CONTROL
WITH ANNUNCIATOR
106 7.23 WIRING DIAGRAM---DUAL CONTROL
107 7.24 WIRING DIAGRAM---DUAL CONTROL
WITH ANNUNCIATOR

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all oftheir products so they can be op-
erated safely. However, the responsibility for safe
operation rests with those who use and maintain
these products. The following safety precautions
are offered as a guide which, if conscientiously fol-
lowed, will minimize the possibility of accidents
throughout the useful life of this equipment.
The compressor should be operated only by those
whohavebeentrainedanddelegatedtodoso,and
who have read and understood this Operator’s
Manual. Failure to follow the instructions, proce-
dures and safety precautions in thismanual canre-
sult in accidents and injuries. Read this manual
prior to startup.
NEVER start the compressor unless it is safe to do
so. DO NOT attempt to operate the compressor
with a known unsafe condition. Tag the compres-
sor and render it inoperative by disconnecting and
locking out all power at source or otherwise disab-
ling itsprime mover, soothers whomay not knowof
the unsafe condition, cannot attempt to operate it
until the condition is corrected.
Install, use and operate the compressor only in full
compliance with allpertinent regulations andallap-
plicable Federal, State, and Local codes, stan-
dards and regulations.
DO NOT modify the compressor and/or controls in
any way except with written factory approval.
While not specifically applicable to all types ofcom-
pressors with all types ofprime movers, most ofthe
precautionary statements contained herein are ap-
plicable to most compressors and the concepts
behind these statements are generally applicable
to all compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor,
owners, employers and users should become fa-
miliar with, and comply with, all applicable regula-
tions and any applicable Federal, State and Local
codes, standards, and regulations relative to per-
sonal protective equipment, such as eye and face
protective equipment, respiratory protective equip-
ment, equipment intended to protect the extremi-
ties, protective clothing, protective shields and bar-
riers and electrical protective equipment, as well as
noise exposure administrative and/or engineering
controls and/or personal hearing protective equip-
ment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow---limiting valve be-
tween the service air outlet and the shut---off
(throttle) valve, either at the compressor or at any
other point along the air line, when an air hose ex-
ceeding 1/2” (13mm) inside diameter is to be con-
nected to the shut---off (throttle) valve, to reduce
pressure in case of hose failure, per all applicable
Federal, State and Local codes, standards and
regulations.
B. Whenthehoseistobeusedtosupplyaman-
ifold, install an additional appropriate flow---limiting
valve between the manifold and each air hose ex-
ceeding 1/2” (13mm) inside diameter that is to be
connected to the manifold to reduce pressure in
case of hose failure.
C.Provideanappropriate flow---limiting valve atthe
beginning of each additional 75 feet (23m) of hose
inruns of air hose exceeding 1/2”(13mm) inside di-
ameter to reduce pressure in case of hose failure.
D. Flow---limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
in accordance with their manufacturer’s recom-
mendations.
E. DO NOT use air tools that are rated below the
maximum rating of thecompressor.Select air tools,
airhoses, pipes, valves, filters, and otherfittings ac-
cordingly. DO NOT exceed manufacturer’s rated
safe operating pressures for these items.
F. Secure all hose connections by wire, chain or
other suitable retaining devices to prevent tools or
hose ends from being accidentally disconnected
and expelled.
G. Open fluid filler cap only when compressor is
not running and is not pressurized. Shut down
the compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
H. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers,
and before attempting to refill optional air lineanti---
icer systems with antifreeze compound.
I.Keep personnel outof linewith andaway fromthe
discharge opening ofhoses ortools or other points
of compressed air discharge.
J.Use airat pressures less than 30psig(2.1 bar)for
cleaning purposes, and then only with effective
chip guarding and personal protective equipment.
K. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
L. DO NOT tamper with sump and unit (if pro-
vided) relief valves. Check the relief valve as rec-
ommended in the Maintenance Section of this
manual or at a minimum of at least weekly to make
sure itis notblocked, clogged, obstructed orother-
wise disabled. DO NOT change the factory setting
of the relief valve.
M. If the compressor is installed in an enclosed
area, it is necessary to vent the relief valve to the
outside of the structure or to an area of non---expo-
sure.

Section 1
SAFETY
2
1.4 FIRE AND EXPLOSION
WARNING
!
When installing a Base Load Transfer (BLT) Sys-
tem, remove jumpers between 16---17 & 18---19
(Dual Control Compressors) so the other com-
pressor does not backfeed defeating the shut-
down circuitry.
A.Clean up spills of lubricant or other combustible
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool.
Then keep sparks, flames and other sources of
ignition away and DO NOT permit smoking in the
vicinity when checking or adding lubricant orwhen
refilling air line anti---icer systems with antifreeze
compound.
C.DO NOT permit fluids, including air line anti---
icer system antifreeze compound or fluid film to ac-
cumulate on, under, or around acoustical material,
oron any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down
using an aqueous industrial cleaner or steam---
clean as required. If necessary, remove acoustical
material, clean all surfaces and then replace
acoustical material. Any acoustical material with a
protective covering that has been torn or punc-
tured should be replaced immediately to prevent
accumulation ofliquids or fluid film within the mate-
rial.DONOTuse flammable solvents for cleaning
purposes.
D. Disconnect and lockoutall powerat sourceprior
to attempting any repairs or cleaning of the com-
pressor or of the inside of the enclosure, if any.
E.Keepelectrical wiring, including all terminals and
pressure connectors in good condition. Replace
any wiring that has cracked, cut abraded or other-
wise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals
and pressure connectors clean and tight.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts
such as terminals to avoid arcing which might
serve as a source of ignition.
G. Remove any acoustical material or other materi-
al that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to
attempting weld repairs.
H. Keep suitable fully charged fire extinguisher or
extinguishers nearby when servicing and operat-
ing the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compressor.
J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate flow
of lubricant or with degraded lubricant.
K. DO NOT attempt to operate the compressor in
anyclassification ofhazardous environment unless
the compressor has been specially designed and
manufactured for that duty.
1.5 MOVING PARTS
A. Keep hands, arms and other parts of the body
and also clothing away from couplings, fans and
other moving parts.
B. DO NOT attempt to operate the compressor
with the fan, coupling or other guards removed.
C.Wearsnug---fitting clothing and confinelong hair
when working around this compressor, especially
when exposed to hot or moving parts.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
E.Make sure all personnel are out ofand/or clear of
the compressor prior to attempting to start or oper-
ate it.
F. Disconnect and lock out all power at source and
verifyat the compressor that all circuits are de---en-
ergized to minimize the possibility of accidental
start---up or operation, prior to attempting repairs
or adjustments. This is especially important when
compressors are remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, or other liq-
uids to minimize the possibility of slips and falls.
1.6 HOT SURFACES, SHARP EDGES AND SHARP
CORNERS
A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners.
B. Keep all parts ofthe body away from all points of
air discharge.
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
any Federal, State or Local Codes or regulations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment.
B. DO NOT use air line anti---icer systems in air
lines supplying respirators or other breathing air
utilization equipment and DO NOT discharge air
from these systems in unventilated or other con-
fined areas.

Section 1
SAFETY
3
C. Operate the compressor only in open or ade-
quately ventilated areas.
D. Locate the compressor or provide aremote inlet
so that it is not likely to ingest exhaust fumes or oth-
er toxic, noxious or corrosive fumes or substances.
E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken to
avoid accidental ingestion and/or skin contact. In
the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event of
skin contact. Consult the compressor operator’s
manual lubrication section for information pertain-
ing to compressor fluid fill.
F. Wear goggles or a full face shield when adding
antifreeze compound to air line anti---icer systems.
G. If air line anti---icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for 15 minutes. A physician, preferably an
eye specialist, should be contacted immediately.
H. DO NOT store air line anti---icer system anti-
freeze compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful, orfatal ifswallowed. Avoidcontact withthe
skin or eyes and avoid breathing the fumes. If swal-
lowed, induce vomiting by administering a table-
spoon of salt, in each glass of clean, warm water
until vomit is clear, then administer two teaspoons
of baking soda in a glass of clean water. Have pa-
tient lay down and cover eyes to exclude light. Call
a physician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained infull compliance withall applicable Federal,
State and Local codes, standards and regulations,
including those of the National Electrical Code, and
also including those relative to equipment ground-
ing conductors, and only by personnel that are
trained, qualified and delegated to do so.
B. Keep all parts of the body and any hand---held
tools or other conductive objects away from ex-
posed live parts of electrical system. Maintain dry
footing, stand on insulating surfaces and DO NOT
contact any other portion of the compressor when
making adjustments or repairs to exposed live
parts of the electrical system. Make all such adjust-
ments or repairs with one hand only, so as to mini-
mize the possibility of creating a current path
through the heart.
C.Attempt repairs inclean, dryand well lighted and
ventilated areas only.
D. DO NOT leave the compressor unattended with
open electrical enclosures. If necessary to do so,
then disconnect, lock out and tag all power at
source so others will not inadvertently restore pow-
er.
E.Disconnect, lockout, and tag all power atsource
prior to attempting repairs or adjustments to rotat-
ing machinery and prior to handling any un-
grounded conductors.
F. Dry test all shutdown circuits prior to starting the
compressor after installation.
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air lifted by he-
licopter must notbe supported by the lifting bail but
by slings instead. In any event, lift and/or handle
only in full compliance with Federal, State and Lo-
cal codes.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
graded members and forloose bolts ornuts prior to
lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condition
and has a rated capacity of at least the weight of
the compressor. If you are unsure of the weight,
then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail or slings.
E.Use guide ropes orequivalent toprevent twisting
or swinging of the compressor once it has been
lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface ca-
pable of safely supporting at least its weight and its
loading unit.
K. When moving compressors by forklift truck, uti-
lize fork pockets if provided. Otherwise, utilize pal-
let if provided. If neither fork pockets or pallet are
provided, then make sure compressor is secure
and well balanced on forks before attempting to
raise or transport it any significant distance.
L. Make sure forklift truck forks are fully engaged
and tipped back prior to lifting or transporting the
compressor.
M. Forklift no higher than necessary to clear ob-
stacles at floor level and transport and corner at
minimum practical speeds.
N. Make sure pallet---mounted compressors are
firmlybolted or otherwise secured tothe pallet prior
to attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured
to its pallet, as uneven floors or sudden stops may

Section 1
SAFETY
4
cause the compressor totumble off,possibly caus-
ing serious injury or property damage in the pro-
cess.
O. DO NOT use the lifting eye bolt on the compres-
sor motor, if supplied, to lift the entire compressor
package.
1.10 ENTRAPMENT
A. If the compressor enclosure is large enough to
hold a person and if itis necessary to enter it toper-
form service adjustments, inform other personnel
before doing so, or else secure and tag the access
door in the open position to avoid the possibility of
others closing and possibly latching the door with
personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

Section 2
DESCRIPTION
5
2.1 INTRODUCTION
Your new Sullair flood---lubricated rotary screw air
compressor will provide you with a unique experi-
ence in improved reliability and greatly reduced
maintenance.
Compared to other types of compressors, the Sull-
air rotary screw is unique in mechanical reliability,
with “no wear” and “no inspection” required of the
working parts within the compressor unit.
Read Section 6 (Maintenance) to see how surpris-
ingly easy it is to keep your air compressor in top
operating condition.
2.2 DESCRIPTION OF COMPONENTS
Refer to Figures 2---1and 2---2.The components
and assemblies of the air compressor are clearly
shown. Thecomplete package includes compres-
sor,electric motor,starter,compressor inlet
system,compressor discharge system,com-
pressor lubrication and cooling system,capac-
ity control system,instrument panel,aftercooler
and a combination separator and trap,all
mounted on a heavy gauge steel frame.
Onair---cooled models, a fandraws airoverthemo-
tor and forces it out through the combined after-
cooler and fluid cooler thereby removing the com-
pression heat from the compressed air and the
cooling fluid.
Onwater---cooled models, a shell and tube heat ex-
changer is mounted on the compressor frame.
Fluid is piped into the heat exchanger where com-
pression heat is removed from the fluid. Another
similar heat exchanger cools the compressed air.
Both air---cooled and water---cooled versions have
easily accessible items such as the fluid filter and
control valves. The inlet air filter isalso easily acces-
sible for servicing.
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Sullair aircompressors feature the Sullair compres-
sor unit, a single---stage, positive displacement,
flood lubricated---type compressor. This unit pro-
Figure 2---1 Sullair Rotary Screw Air Compressor

Section 2
DESCRIPTION
6
Figure 2---2 Sullair Rotary Screw Air Compressor (Typical Air---cooled Compressor Shown)
vides continuous pulse---free compression to meet
your needs. With a Sullair compressor, there is no
maintenance or inspection of the internal parts of
the compressor unit permitted in accordance with
the terms of the warranty.
Sullair 24KT compressors are filled with a fluid
which rarely needs to be changed. In the event a
change of fluid is required, use only Sullair 24KT
fluid. MIXING OF OTHER LUBRICANTS WITHIN
THE COMPRESSOR UNIT WILL VOID ALL WAR-
RANTIES!
Sullair recommends that a 24KT sample be taken
at the first filter change and sent to the factory for
analysis. This is a free service. The sample kit with
instruction and self---addressed container is to be
supplied by your Sullair dealer at start---up. The
user will receive an analysis report with recommen-
dations.
Fluid is injected into the compressor unit in large
quantities and mixes directly with the air as the ro-
tors turn, compressing the air. The fluid flow has
three basic functions:
1. As coolant, it controls the rise of air temperature
normally associated with the heat of compres-
sion.
2. Seals the leakage paths between the rotors and
the stator and also between the rotors them-
selves.
3. Acts as a lubricating film between the rotors al-
lowing one rotor todirectly drive the other, which
is an idler.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air.
Atthis time, the airflows through an aftercooler and
separator, then to your service line while the fluid is
being cooled in preparation for reinjection.
2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
RefertoFigure2--- 3.Thecooling system(air---
cooled version) consists of afan,fan motor,radia-
tor---type aftercooler/fluid cooler,full flow fluid
filter, thermal valve,fluid stop valve and inter-

Section 2
DESCRIPTION
7
Figure 2---3 Compressor Fluid Cooling and Lubrication System
connecting piping and tubing. For water---cooled
models, two shell and tube heat exchangers and a
water---flow regulating valve are substituted for the
radiator---type coolers listed above.
Thepressure inthe receiver/sump causes fluidflow
by forcing the fluid from the high pressure area of
the sump to an area of lower pressure in the com-
pressor unit.
Fluid flows from the bottom of the receiver/sump to
the thermal valve. The thermal valve is fully open
when the fluid temperature is below 170_F(77_C).
Thefluidpassesthroughthethermalvalve,the
main filter and directly to the compressor unit
where it lubricates, cools and seals the rotors and
the compression chamber.
As the discharge temperature rises above 170_F
(77_C), due to the heat of compression, the ther-
mal valve begins to close and a portion of the fluid
then flows through the cooler. From the cooler the
fluid flows to the main filter and then on to the com-
pressor unit.
A portion of the fluid flowing to the compressor is
routed to the anti---friction bearings which support
the rotors inside thecompressor unit. Priortoenter-
ing the compressor unit, this fluid is taken through
the fluid filter, thus assuring properly filtered lubri-
cant for bearing supply.
The fluid filter has areplacement element and anin-
tegral pressure bypass valve. A gauge on the in-
strument panel shows red when the filter needs
servicing. This gauge has a pressure setting lower
than that of the bypass valve. After the initial 50
hour filter change, the gauge will rarely show red
under normal operating conditions.
The fluid stop valve prevents fluid from filling the

Section 2
DESCRIPTION
8
compressor unit when the compressor is shut
down. When the compressor is operating, the fluid
stop valve is held open by air pressure from the
compressor unit allowing a free flow of fluid from
the receiver/sump back to the compressor unit. On
shutdown, the compressor unit pressure is re-
duced, causing the fluid stopvalve toclose andiso-
late the compressor unit from the cooling system.
Water---cooled versions of the compressor have a
water---flow regulating valve (not shown) which op-
erates to conserve water during periods of varying
load on the compressor. This same valve automati-
cally shuts off the water supply when the compres-
sor is shut down. In addition, water---cooled mod-
els have a water pressure switch to prevent opera-
tion with inadequate water pressure.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
TIONAL DESCRIPTION.
Refer to Figure2---4.The compressor unit dis-
charges the compressed air/fluid mixture into the
combination receiver/sump. The discharge check
valve prevents air in the receiver from returning to
the compression chamber after the compressor
has been shut down.
The receiver has three basic functions:
1. It acts as a primary fluid separator.
2. Serves as the compressor fluid sump.
3. Houses the final fluid separator.
The compressed air/fluid mixture enters the receiv-
Figure 2---4 Compressor Discharge System (Typical)

Section 2
DESCRIPTION
9
er and is directed towards the bottom of the sepa-
rator element. The direction of movement is
changed and itsvelocity significantly reduced, thus
causing large droplets offluid toseparate and fall to
the bottom ofthe receiver/sump. The fractional per-
centage of fluid remaining in the compressed air
collects on the surface of the separator element as
the compressed air flows through the separator.
Return lines (or scavenge tubes) lead from the bot-
tom of the separators’ elements to the inlet region
of the compressor unit. Fluid collecting on the bot-
tom of the separator is returned to the compressor
by a pressure differential between the receiver and
the compressor inlet. Visual sight glasses are lo-
cated on the return lines to observe the fluid flow.
There are also orifices in the return line (protected
by strainers) to assure proper flow. A gauge, lo-
cated on the instrument panel, shows red if abnor-
mal pressure drop through the separators devel-
ops. At this time, separator element replacement is
necessary.
The receiver is ASME code rated at 175 psig (12.1
bar)working pressure. A minimum pressure/check
valve, located downstream from the separator, as-
sures a minimum receiver pressure of 55 psig (3.8
bar) during all conditions. This pressure is neces-
sary for proper air/fluid separation and proper fluid
circulation.
Aterminal check valve isincorporated into the mini-
mumpressure/check valvetoprevent compressed
air inthe service line formbleeding back into there-
ceiver on shutdown and during operation of the
compressor in an unloaded condition.
A pressure relief valve (located on the wet side of
the separator) is set to open if the sump pressure
exceeds 175 psig (12.1 bar). A temperature switch
will shut downthe compressor ifthe discharge tem-
perature reaches 235_F (113_C).
All compressor models are equipped with a high
pressure shutdown switch to shut down the com-
pressor at 135 psig (9.3 bar). This prevents the
pressure relief valve from opening under routine
conditions, thereby preventing fluid loss through
the pressure relief valve.
WARNING
!
DO NOT remove caps, plugs, and/or other com-
ponents when compressor is running or pressur-
ized.
Stop compressor and relieve all internal pres-
sure before doing so.
Fluid is added to the sump via a capped fluid filler
opening, placed low on the tank to prevent overfil-
ling ofthesump. Asight glass enables the operator
to visually monitor the sump fluid level.
2.6 CONTROL SYSTEM, FUNCTIONAL DE-
SCRIPTION
RefertoFigure2---5.Thepurposeofthecompres-
sor control system isto regulate the compressor air
intake to match the amount of compressed air be-
ing used. The control system consists of a Sulli-
concontrol,abutterfly valve(located onthe com-
pressor air inlet), a pressure switch,asolenoid
valve and pressure regulator. The functional de-
scription of the control system is described below
in four distinct phases of compressor opera-
tion.The following descriptive text applies to all 12
and 16 Series compressors. For explanatory pur-
pose this description will apply to a compressor
with an operating pressure range of 100 to 110
psig (6.9 to 7.6 bar). A compressor with any other
pressure range would operate in the same manner
except for the stated pressures.
START MODE --- 0 TO 55 PSIG (0 TO 3.8 BAR)
When the compressor START button is depressed,
thesumppressure willquickly risefrom0to 55psig
(0 to 3.8 bar). During this period both the pressure
regulator and the solenoid valve are closed and the
Sullicon Control is inoperative. The spring on the
control holds the butterfly valve fully open and the
compressor pumps at full rated capacity. Therising
compressed air pressure is isolated from the ser-
vice line in this phase by the minimum pressure
valve, set approximately at 55 psig (3.8 bar).
NORMAL OPERATION MODE --- 55 TO 100 PSIG
(3.8 TO 6.9 BAR)
When the compressor air pressure rises above 55
psig (3.8 bar), the minimum pressure valve opens
and delivers compressed air to the service line.
Fromthispointon,thelineairpressure iscontinual-
ly monitored by a line pressure gauge. The pres-
sure regulator and the solenoid valve remain
closed during this phase, keeping the Sullicon
Control inactive.
MODULATING MODE --- 100 TO 110 PSIG (6.9
TO 7.6 BAR)
If less than the rated capacity of compressed air is
being used, the service line pressure will riseabove
100 psig (6.9 bar). The pressure regulator valve
gradually opens, applying air pressure to the dia-
phragm chamber ofthe Sullicon Control which par-
tially closes the butterfly valve on the compressor
air inlet, reducing the amount of air entering the
compressor until it matches the amount ofair being
used. The control system functions continually in
this manner, between the limits of 100 to 110 psig
(6.9 to 7.6 bar), in response to varying demands
from the service line.
Thepressure regulator hasan orificewhich vents a
small amount of air to the atmosphere when the
pressure regulator controls the butterfly valve. The
orifice also bleeds any accumulated moisture from
the Sullicon Control.

Section 2
DESCRIPTION
10
Figure 2---5A Control System, Sequence of Operation (Typical)
SOLENOID
SOLENOID

Section 2
DESCRIPTION
11
Figure 2---5B Control System, Sequence of Operation (Typical)
SOLENOID
UNLOAD --- IN EXCESS OF 110 PSIG (7.6 BAR)
LINE PRESSURE
When no air is being used, the service line pres-
sures rises to the setting (cut---out pressure) of the
pressure switch. The pressure switch opens, inter-
rupting the electrical powerto thesolenoid valve.At
this time, the solenoid valve allows dry sump tank
airpressure tobe applied directly tothe control dia-
phragm, keeping the butterfly valve closed. Simul-
taneously, the solenoid valve sends a pneumatic
signal to the blowdown valve. The blowdown valve
opens the sump to the atmosphere, reducing the
sump pressure to approximately 40 to 50 psig (2.8
to 3.8 bar). The check valve in the air service line
prevents line pressure from returning to the sump.
When the line pressure drops to the low setting
(cut---in pressure) of the pressure switch (usually
100 psig [6.9 bar] on low pressure compressors
and 115 psig [7.9 bar] on high pressure compres-
sors), the pressure switch closes, re---energizing
the three---way solenoid valve and allowing the
blowdown valve to close. The re---energized sole-
noid valve again prevents line pressure from reach-
ing the Sullicon Control. Should the pressure begin
to rise, the pressure regulator will resume its nor-
mal function as previously described.
For a compressor with varied periods of time when
there are no air requirements, a “dual control” op-
tion is available. This option allows you to set the
compressor in an automatic position whereby the
compressor will shut down when no compressed
air requirement is present and restart as com-
pressed air is needed.
2.7 AIR INLET SYSTEM, FUNCTIONAL DE-
SCRIPTION
RefertoFigure2--- 6.Thecompressor inlet sys-
tem consists of a dry---type air filter,arestriction
gauge and a control valve.
The restriction gauge, located on the compressor
instrument panel, indicates the condition of the air
filter by showing red when filter maintenance is re-
quired.
The butterfly---type air inlet valve directly controls
the amount of air intake to the compressor in re-
sponse tothe operation ofthe Sullicon Control (see
Section 2.6,Control System).
See Section 6 for Air Filter Maintenance Proce-
dures.
2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL
DESCRIPTION
Refer toFigure2---7forspecific location ofparts de-
scribed. The instrument panel groupconsists ofa
panel containing the line pressure,sump pres-
sure and discharge temperature gauges,theair
filter,theseparator element and the fluid filter,

Section 2
DESCRIPTION
12
Figure 2---6 Compressor Air Inlet System
restriction gauges,alongwithSTART and STOP
pushbuttons and an hourmeter.
Refer toFigure2---7for locations of the following in-
dicators and controls:
Sand 100HPThe line (terminal) pressure gauge
is connected to the dry side of the receiver down-
stream from the check valve and continually moni-
tors the air pressure.
SThe sump pressure gauge continually monitors
the sump pressure at the various load and/or un-
load conditions.
SThe discharge temperature gauge monitors
the temperature of the air leaving the compressor
unit. For both air---cooled and water---cooled com-
pressors the normal reading is approximately
180_F(82
_C) when the ambient temperature is
less than 80_F(27
_C).
SThe air filter restriction gauge monitors the con-
dition of the air intake filter and shows in the red
zone(20”to30”water [51to76 cm])when filter ser-
viceis required (see Figure2---6).
SThe START pushbutton turns the compressor on.
SThe STOP pushbutton turns the compressor off.
SThe hourmeter records cumulative hours of op-
eration for the compressor and is useful for plan-
ning and logging service operations.
SThe separator maintenance gauge monitors
the condition of the separator elements and shows
in the red zone when the element restriction is ex-
cessive.
SThe fluid filter maintenance gauge monitors
the condition of the bearing filter element and
shows in the red zone when the element should be
changed.
SThe red light on the instrument panel indicates
when power to the compressor is supplied.
SThegreen light indicates when the compressor is
running.
SThe optional dual control package is supplied
with an amber auto mode indicator light to indicate
that the unit is running in the automatic mode. A
position selector switch provides selection be-
tween hand operation and automatic control.
Figure 2---7 Instrument Panel Group

Section 3
SPECIFICATIONS
13
3.1 TABLE OF SPECIFICATIONS
LS--12 60 HZ (AIR-- OR WATER --COOLED) (I)
MODEL HP/KW CAPACITY LENGTH WIDTH HEIGHT (VI)WEIGHT(
VI)dBA( VII) dBA (VII)
(ACFM/M!/MIN) (IN/MM) (IN/MM) (IN/MM) (LB/KG) w/ encl. / w/encl. /
w/o encl. w/o encl.
(air--cooled) (water--cooled)
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------------------------------------------------------------------------------------------------------------
L(II) 40/30 90/5.38 72/1830 48/1220 60/1524 2060/934 83/89 77/82
50/37 235/6.65 72/1830 48/1220 60/1524 2060/934 84/89 76/83
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ------------------------------------------------------------------------------------------------------------
H(III) 40/30 175/4.96 72/1830 48/1220 60/1524 2060/934 83/89 84/89
50/37 215/6.09 72/1830 48/1220 60/1524 2060/934 84/89 76/83
60/45 260/7.36 72/1830 48/1220 60/1524 2350/1066 85/90 77/84
LS--16 60 HZ (AIR-- OR WATER --COOLED) (I)
MODEL HP/KW CAPACITY LENGTH WIDTH HEIGHT WEIGHT dBA dBA
(ACFM/M!/MIN) (IN/MM) (IN/MM) (IN/MM) (LB/KG) w/ encl. / w/encl. /
w/o encl. w/o encl.
(air--cooled) (water--cooled)
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------------------------------------------------------------------------------------------------------------
L60/45 300/8.5 72/1829 48/1219 60/1524 2350/1066 84/89 82/89
75/55 370/10.4 72/1829 48/1219 60/1524 2680/1216 84/89 82/89
100/75 475/13.5 72/1830 48/1220 62.5/1588 2750/1247 84/89 83/85
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ------------------------------------------------------------------------------------------------------------
H(II) 60/45 280/7.93 72/1830 48/1220 60/1524 2590/1175 84/89 82/89
75/55 330/9.34 72/1830 48/1220 60/1524 2680/1216 84/89 82/89
100/75 475/13.5 72/1830 48/1220 62.5/1588 2750/1247 84/89 83/85
ENCLOSURE
(OPT) (IV) 72/1829 48/1220 62/1588 500/227
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------------------------------------------------------------------------------------------------------------
EES PACKAGE
(OPT) (IV)89/2262 48/1220 130/2618 510/259
(I) Includes standard and 24KT. New series pressure range designations appearing after model number are as follows:
“L” -- 7.0 to 7.5 bar “H” -- 8.0 to 8.5 bar
(II) Model L Maximum Pressure: 110 psig/7.6 bar
(III) Model H Maximum Pressure: 125 psig/8.6 bar
(IV) The weights shown for the Enclosure and EES packages does not include the weight of the compressor package.
(V) An additional length of 4 in./102mm is needed for servicing the separator; 9 in./229mm for enclosure models.
(VI) Add 1450 lbs/658 kg for enclosure models.
(VII) Ratings for dBA at one meter.
COMPRESSOR: 24KT MODELS STANDARD MODELS
Type: Rotary Screw Rotary Screw
Standard Operating Pressure (II): 100 psig (6.9bar) (L) 100 psig (6.9bar) (L)
115 psig (7.9bar) (H) 115 psig (7.9bar) (H)
Bearing Type: Anti---Friction Anti---Friction
Ambient Temperature (Max.) (III): 105_F(41
_C) 105_F(40 _C)
Cooling: Pressurized Fluid Pressurized Fluid
Compressor Fluid: Sullair 24KT Coolant Fluid SRF1/4000 (12 & 16 Series
[60 & 75HP])
Sullube 32 (16 Series
[100HP])
Sump Capacity: 9.0 U.S. gallons (34 liters) 9.0 U.S. gallons (34 liters)
(40 and 50HP) (40 and 50HP)
10.0 U.S. gallons (38 liters) 10.0 U. S. gallons (38 liters)
(60 and 75HP) (60 and 100HP)
Control: Electro --- Pneumatic Electro --- Pneumatic

Section 3
SPECIFICATIONS
14
3.1 TABLE OF SPECIFICATIONS (continued)
MOTOR: (60 Cycle Compressors)
24KT MODELS STANDARD MODELS
Size: 40,50,60, 75HP 40,50,60, 75 & 100 HP
Type: C---Flanged, Open Dripproof, 460V, A.C., C---Flanged, Open Dripproof, 460V, A.C.,
Three Phase, 60 Cycles Three Phase, 60 Cycles
40_C Maximum Ambient Temperature 40_C Maximum Ambient Temperature
Options Available: 200V, 230V and 575V Options Available: 200V, 230V and 575V
T.E.F.C. Also Available T.E.F.C. Also Available
Starter: 460V Full Voltage Magnetic 460V Full Voltage Magnetic
Options Available: 200V, 230V and 575V Options Available 200V, 230V and 575V
Speed: 1770 RPM 1770RPM and 3550RPM (100HP)
3.2 LUBRICATION GUIDE---STANDARD COM-
PRESSORS (All 12 Series; 16 Series --- 60 and
75HP)
Sullair standard compressors are filled with SRF
1/4000 fluid factory fill.
WARNING
!
Mixing of other lubricants within the compressor
unit will void all warranties!
SRF 1/4000 fluid should be changed every 4000
hours or once a year, whichever comes first. The
fluid should be changed more frequently under se-
vere operating conditions, such as high ambient
temperatures coupled with high humidity, or when
high particle level, corrosivegases orstrong oxidiz-
ing gases are present in the air.
For extended life synthetic lubricants contact the
nearest Sullair representative.
Maintenance of all other components is still recom-
mended as indicated in the Operator’s Manual.
3.3 LUBRICATION GUIDE --- STANDARD COM-
PRESSORS (16 Series --- 100HP)
Sullair standard compressor are filled with Sullube
32 fluid as factory fill.
WARNING
!
Mixing of other lubricants within the compressor
unit will void all warranties!
Sullube 32 fluid should be changed every 8000
hours or once a year, whichever comes first. The
fluid should be changed more frequently under se-
vere operating conditions, such as high ambient
temperatures coupled with high humidity, or when
high particulate level, corrosivegases orstrongoxi-
dizing gases are present in the air.
WARNING
!
“The Plastic Pipe Institute recommends against the
use of thermoplastic pipe to transport compressed
air or other compressed gases in exposed above
ground locations, e.g. in exposed plant piping.” (I)
Sullube 32should not beused with PVC piping sys-
tems. It mayaffectthebond atcemented joints. Cer-
tain other plastic materials may also be affected.
(I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972.
Maintenance of all other components is still recom-
mended as indicated in the Operator’s Manual.
3.4 LUBRICATION GUIDE---24KT COMPRES-
SORS
Sullair 24KT compressors are filled with a lubricant
which rarely needs to be changed. In the event a
change of fluid is required, use only Sullair 24KT
fluid.
WARNING
!
Mixing of other lubricants within the compressor
unit will void all warranties!
Sullair recommends that a 24KT sample be taken
at the first filter change and sent to the factory for
analysis. This is a free service. A sample kit with in-
structions and self---addressed container is to be
supplied by your Sullair Representative at start---
up. The user will receive an analysis report with rec-
ommendations.
APPLICATION GUIDE
Sullair encourages the user to participate in a fluid
analysis program with the fluid suppliers. This
could result in a fluid change interval differing from
that stated in the manual. Contact your Sullair deal-
er for details.

Section 4
INSTALLATION
15
4.1 MOUNTING OF COMPRESSOR
A foundation or mounting capable of supporting
the weight of the compressor, and rigid enough to
maintain the compressor frame level and the com-
pressor in alignment, is required. The compressor
frame must be leveled and secured with foundation
bolts, and full uniform contact must be maintained
between the frame and foundation. No piping
loads shall be transmitted to the compressor at the
external connections.
4.2 VENTILATION AND COOLING
For air---cooled compressors, select a location to
permit sufficient unobstructed air flowing in and out
to the compressor to keep the operating tempera-
ture stable. The minimum distance that the com-
pressor should be from surrounding walls is three
(3) feet (0.9 m). To prevent excessive ambient tem-
perature rise, it is imperative to provide adequate
ventilation.
For water---cooled compressors, it is necessary to
check the cooling water supply. The water system
must be capable of supplying the following flows:
WATER TEMP. WATER FLOW
40HP
50HP
60HP
75HP
(water pressure should be between
25 and 75 psig (1.7 and 5.2 bar).
100HP
AT 70_F(21
_C)
in GPM (LPM) AT 80_F(27
_C)
in GPM (LPM)
6(22.7) 8(30.3)
7(26.5) 10.5 (39.75)
9(34.1) 11.5 (44.5)
10.5 (39.75) 14 (53)
11.75 (44.5) 15.75 (59.6)
TABLE 1 --- WATE R FLOW REQUIREMENTS
The proper water flow as indicated inTable 1must
be maintained at all times. These figures apply to a
compressor running at full load with an aftercooler.
For cooler water or a partially loaded compressor,
slightly less water is required. However, for hotter
water the flow requirements are significantly great-
er.
Table2shows the ventilation requirements neces-
sary to keep the compressor running at a normal
operating temperature. The fan air requirement is
the volume of air which must flow through the com-
pressor for proper ventilation. The specified heat
rejection requirement is the amount of heat that is
radiated by the compressor. This heat must be re-
moved to assure a normal operating temperature.
With air---cooled compressors it is possible to use
this heat for space heating, providing no additional
pressure drop is created across the fan. Consult a
Sullair office for assistance in utilizing this heat.
DO NOT install a water---cooled or an air---cooled/
aftercooled compressor where itwill be exposed to
temperatures less than 32_F(0_C).
4.3 SERVICE AIR PIPING
Service air piping should be installed as shown in
Figure4--- 1.Ashut--- offvalveshouldbeinstalledto
isolate the compressor from the service line if re-
quired. Also notice that the service line should be
equipped with water legs and condensate drains
throughout the system.
WARNING
!
“The Plastic Pipe Institute recommends against the
use of thermoplastic pipe to transport compressed
air or other compressed gases in exposed above
ground locations, e.g. in exposed plant piping.” (I)
Sullube 32should not beused with PVC piping sys-
tems. It mayaffectthebond atcemented joints. Cer-
tain other plastic materials may also be affected.
(I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972.
4.4 COUPLING ALIGNMENT CHECK
No coupling alignment is required.
4.5 FLUID LEVEL CHECK
The air compressor isalso supplied with the proper
amount of fluid. However, it is necessary to check
the fluid level at installation. The level is checked by
looking at the sight glass located near the sump. If
the sump is properly filled, the fluid level should be
at the normal reading.
4.6 ELECTRICAL PREPARATION
Interior electrical wiring is performed at the factory.
Required customer wiring is minimal, but should
be done by a qualified electrician in compliance
withOSHA, National Electrical Code, and any other
TABEL 2--- VENTILATION REQUIREMENTS
Cooling Type Air---cooled w/Aftercooler Water---cooled
Motor HP 50
Fan Air CFM 6,000
Heat Rejection BTU/Hour 153,360
40 60 75
6,000 7,500 7,500
123,250 183,800 229,800
50
1,440
13,300
40 60 75
1,440 2,845 2,845
11,200 15,800 19,800
(I)
(I)Applies to compressors with canopy only (vent fan).
100
7,500
302,410
100
2,845
22,410